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Balancing operability and fuel efficiency in the truck and bus industry
Realize innovation.Unrestricted © Siemens AG 2017
Unrestricted © Siemens AG 2017Page 2 Siemens PLM Software
Agenda
• The truck and bus industry is evolving
• Model-based systems engineering for truck and bus
• The voice of our customers• Conclusion
Unrestricted © Siemens AG 2017Page 3 Siemens PLM Software
Agenda
• The truck and bus industry is evolving
• Model-based systems engineering for truck and bus
• The voice of our customers• Conclusion
Unrestricted © Siemens AG 2017Page 4 Siemens PLM Software
Stringent emissions regulations Irreplaceable value of brand attributes
Mass customization and personalization
The truck and bus industry is evolving
Worldwide race for innovation
Unrestricted © Siemens AG 2017Page 5 Siemens PLM Software
Which implications for truck and bus design?
• Powertrain hybridization
• Vehicle weight reduction
• Systems integration optimization
• Best compromise between fuel economy, performance, drivability, comfort and cost
• Vertical integration
• Growing systems complexity
• Predictive maintenance
• Autonomous driving
Stringent emissions regulations Irreplaceable value of brand attributes
Worldwide race for innovation
• Software-intensive systems
• Shift from mechanical to software systems
Mass customization and personalization
Unrestricted © Siemens AG 2017Page 6 Siemens PLM Software
One constant. Addressing these engineering challenges …… without compromising time-to-market, quality and cost
Unrestricted © Siemens AG 2017Page 7 Siemens PLM Software
Systems-driven product development
Predictive Engineering AnalyticsRole in systems-driven product development
Predictive Engineering AnalyticsSystem mockup
Managed in PLM context - Multi-domain traceability, change and configuration
TEST
Digital twin
1D
CFD
Exploration - Analytics - Reporting
3D
Unrestricted © Siemens AG 2017Page 8 Siemens PLM Software
Introducing Simcenter™ for Predictive Engineering Analytics
Simcenter™
Unrestricted © Siemens AG 2017Page 9 Siemens PLM Software
Simcenter™ Portfolio for Predictive Engineering Analytics LMS Imagine.Lab
LMS Imagine.Lab Amesim
LMS Imagine.Lab
System Synthesis
Unrestricted © Siemens AG 2017Page 10 Siemens PLM Software
>30 libraries
>4,000 multi-physics models
Simcenter™ Portfolio for Predictive Engineering Analytics LMS Imagine.Lab
Open & customizable
Pre-design
Systems sizing & integration
Performance balancing
Controls validation
Industry-specific
Internal combustionTransmissionThermal systemsVehicle dynamicsElectrical systemsLanding gear & flight controlsEngine equipmentEnvironmental control systemsFuel systemsElectrical aircraftPumps & compressorsElectrohydraulic valvesFluid actuation systemsHeat exchangersHeat pumps / refrigerators
Scalable simulation
Connecting mechanical and
controls
Model reduction for real-time simulation
HydraulicsPneumatics
Thermal Electrical
Mechanical Signals Process & data
Management
Model-based system testing
Co-simulation
Unrestricted © Siemens AG 2017Page 11 Siemens PLM Software
Engineering servicesExperience and global talent for valued customer partnerships
CD-adapco Engineering
LMS Engineering
Unrestricted © Siemens AG 2017Page 12 Siemens PLM Software
Agenda
• The truck and bus industry is evolving
• Model-based systems engineering for truck and bus
• The voice of our customers• Conclusion
Unrestricted © Siemens AG 2017Page 13 Siemens PLM Software
Model-based systems engineering for truck and bus design
CHALLENGE:Balancing operability, fuel efficiency and other key vehicle attributes
Unrestricted © Siemens AG 2017Page 14 Siemens PLM Software
From vehicle synthesis to sub-systems optimization…
Multiple driving cycles
Scenarios
Fuel eco & emissions
Performance attributes
Vehicle model – Synthesis and analysis
Driver
Engine
Transmission
Vehicle
Safety and ComfortThermal management
Productivity
n l Control
Sub-systems models and tools
Engine Transmission Vehicle Thermal Fluids Electrics Control
Unrestricted © Siemens AG 2017Page 15 Siemens PLM Software
Application 1: hybridization of a busFuel economy estimation
Objectives• Reduce the operating cost of a city bus by improving the fuel
economy• Shift the engine operating torque to get the optimal efficient
range and recover the energy lost during braking
Solution• Develop an electrified powertrain including an electric motor, an
inverter and a super-capacitor• Estimate the gain in term of fuel economy on the SORT cycle, a
specific bus cycle developed by International Association of Public Transport (UITP)
Unrestricted © Siemens AG 2017Page 16 Siemens PLM Software
Application 1: hybridization of a busConventional bus
LMS Amesim model of the diesel bus
Mission profile and driver commandMechanical power
and fuel consumption
Unrestricted © Siemens AG 2017Page 17 Siemens PLM Software
Application 1: hybridization of a busHybrid electric bus: map-based model for electrics
LMS Amesim model of the hybrid bus
Tabulated electrical machine for pre-sizing with rescaling tool
and GUI (maximum torque and efficiency)
Unrestricted © Siemens AG 2017Page 18 Siemens PLM Software
Application 1: hybridization of a busHybrid electric bus: functional model for electrics
LMS Amesim model of the hybrid busFunctional electrical modeling for mechanical dynamics,
control analysis and losses estimation
Functionaldynamic machine
Functionalmachinecontrol
Unrestricted © Siemens AG 2017Page 19 Siemens PLM Software
Application 1: hybridization of a busHybrid electric bus: comparison with diesel vehicle
Fuel consumption reduction and
ICE power
Unrestricted © Siemens AG 2017Page 20 Siemens PLM Software
Application 2: manual transmissionEfficiency analysis
Objective:• Analyze the power losses and monitor the global
efficiency of a mechanical transmission in function of the vehicle speed
Requirements:• Account for the power losses each family of
component: roller bearing, journal bearing, gear contact, oil paddling, ring friction…
Mechanical transmission layout and portion of the corresponding LMS Amesim model
Unrestricted © Siemens AG 2017Page 21 Siemens PLM Software
Application 2: manual transmissionLosses calculation
Gear trains• Different levels of complexity:
• Simple transformer ratio• Constant losses• Variable losses defined with tables• Calculated contact losses based on geometry• Paddling and side contact losses• Clearance and contact stiffness
Bearings• Different levels of complexity:
• Tabulated losses• Detailed losses based on geometry and loads• With/Without thermal impact• Bearing losses due to oil & material deformations• Models based on semi-empiric equations and
manufacturers coefficients• Generic formulation, NTN or Timken equations
Unrestricted © Siemens AG 2017Page 22 Siemens PLM Software
Application 2: manual transmissionResults
Visualization of losses and global driveline efficiency: batch run is performed to reach 24 stationary points: 6 gears, 2 input torques, 2 temperatures, 1 engine rotary velocity
Unrestricted © Siemens AG 2017Page 23 Siemens PLM Software
Application 3: truck with closed-loop fan controlEnhance fuel consumption prediction
Objective• Analyze the fuel consumption of a truck including the power consumption of
auxiliaries and especially the engine cooling fan (up to 15% of the engine power)
Requirement• Captured thermal dynamics of the engine cooling system and enable closed-
loop fan control
FTP-72 or UDDS cycle
Energy management model of a truck
Unrestricted © Siemens AG 2017Page 24 Siemens PLM Software
Application 3: truck with closed-loop fan controlStep 1: vehicle performance/fuel consumption simulator
Objective • Impact of engine temperature on fuel consumption
Requirement• Iso-thermal simulation
Dependence of fuel consumption on the engine temperature: at low temperature,
friction is high leading to increased the fuel consumption
Unrestricted © Siemens AG 2017Page 25 Siemens PLM Software
Application 3: truck with closed-loop fan controlStep 2: thermal dynamics of the engine cooling system
Objective• Estimate the power consumption of the engine cooling fan
Requirement• Capture thermal dynamics of the engine cooling system and enable
closed-loop fan control
Fan control depends on engine coolant temperature.When the fan is activated, it consumes energy
Heat exchanger stacking: study the trade-off between different configurations
Unrestricted © Siemens AG 2017Page 26 Siemens PLM Software
Application 3: truck with closed-loop fan controlStep 2: thermal dynamics of the engine cooling system
Engine thermal management: coolant
temperature, thermostat opening
and fan control
Fan power consumption
depends on fan control
Unrestricted © Siemens AG 2017Page 27 Siemens PLM Software
Agenda
• The truck and bus industry is evolving
• Model-based systems engineering for truck and bus
• The voice of our customers• Conclusion
Unrestricted © Siemens AG 2017Page 28 Siemens PLM Software
Voith TurboMaking greener city buses using LMS Imagine.Lab Amesim
Enhance automatic transmission by acting on hydraulic valves
• Reduced testing time and number of prototype iterations
• Developed improved design for hydraulic valves
• Enabled continuous improvement to the design and development processes
“[LMS Amesim] definitely helped to streamline the design and development of our transmission systems, making them readily available for the transportation market.”
Bernhard Höfig, Mechatronics and Simulation
• Use 1D multi-domain system to predict dynamic behavior of systems and subsystems• Leverage scope and quality of LMS Amesim libraries
Automatic transmission analysisLMS Imagine.Lab Amesim model
Link to the story
Unrestricted © Siemens AG 2017Page 29 Siemens PLM Software
ScaniaReducing driveline modeling time using LMS Imagine.Lab Amesim
Analyzing drivability, NVH, comfort and vehicle performance
• Reduced modeling time by a factor of 2 to 10
• Accelerated CPU time• Streamlined development
processes“LMS Amesim allows Scania to first understand the main issues, and then reduce modeling time […]. Moreover, we can run some simulations faster than the real time”
Fredrik Birgersson, Senior Engineer
• Study drivability, gearbox losses and oil flow, NVH comfort and pneumatic actuation• Perform fast simulations using real-time capabilities
Drivability analysis Clutch model in LMS Imagine.Lab Amesim
Link to the story
Unrestricted © Siemens AG 2017Page 30 Siemens PLM Software
Dongfeng Commercial VehicleOptimizing engine control strategies with LMS Imagine.Lab Amesim
Boosting fuel efficiency with innovative energy recovery technology
• Optimized engine cooling controls strategies
• Analyzed behavior of the combustion, cooling and lubrication subsystems
• Studied Rankine cycle technology before the first prototype was available
“Our research and development activity around the Rankine cycle technology wouldn’t be possible without the two-phase flow library of LMS Amesim...”
Zhang Xin, Controls Engineer
• Design an efficient engine cooling system with advanced controls strategies• Analyze the impact of the exhaust heat recovery technology
Co-simulation LMS Amesim and Simulink® Rankine cycle loop model
Link to the story
Unrestricted © Siemens AG 2017Page 31 Siemens PLM Software
University of Belgrade, Faculty of Mechanical EngineeringAnalyzing hybrid transit bus fuel economy with LMS Imagine.Lab Amesim
Real conventional bus identification and virtual hybridization
• 16% fuel consumption reduction assessed with LMS Amesim
• Identified set of test data required for fuel consumption simulations
• Fuel economy compared for several hybrid control algorithms
“LMS Amesim provides a graphical programming interface and an extensive set of validated components organized in different libraries for modeling and analyzing system performance.”
Marko Kitanović, M.Sc., Teaching and Research Assistant, Internal Combustion Engines Department
• Import real driving vehicle and powertrain measurement data into LMS Amesim
• Compare ultra capacitors-based hybrid vehicle with conventional one
Optimal state of charge (SOC) trajectoryConventional hybrid bus LMS Amesim model
Unrestricted © Siemens AG 2017Page 32 Siemens PLM Software
Agenda
• The truck and bus industry is evolving
• Model-based systems engineering for truck and bus
• The voice of our customers• Conclusion
Unrestricted © Siemens AG 2017Page 33 Siemens PLM Software
Model-based systems engineering solutions Unique value proposition for truck and bus design
Reduce development cost with fewer prototypes
Virtually assess systems interactions
Find the best comprise to fit both regulations and
market requirements
Study the influence of control strategies on fuel consumption, emissions
and performances
Analyze vehicle/powertrain
architectures earlier in the development cycle
Balance critical attributes:fuel economy,
performances, passenger comfort and drivability
Unrestricted © Siemens AG 2017Page 34 Siemens PLM Software
Explore how the Simcenter portfolio can help you optimize designs and deliver innovations faster, with greater confidence
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Unrestricted © Siemens AG 2017Page 35 Siemens PLM Software
Romain NicolasBusiness Development LMS Amesim
Siemens PLM / France / Simulation & Test Solutions
E-mail:[email protected]
Realize innovation.